Tool and Method For Repairing An Arc Welding Torch

ABSTRACT

A tool for repairing an interior surface of a conductor tube comprises an elongate body having a proximal end and a distal end. The tool includes a profiled end surface that mates into the interior surface of the conductor tube. The tool includes a central protrusion that extends from the profiled end surface for aligning the tool within the internal passageway of the conductor tube. An imparted force is exerted on the proximal end and the force reshapes the interior surface of the conductor tube around the profiled end surface.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. non-provisional applicationSer. No. 14/540,846 filed on Nov. 13, 2014, entitled “TOOL AND METHODFOR REPAIRING AN ARC WELDING TORCH,” which claims the benefit of U.S.provisional application Ser. Nos. 61/903,950 filed on Nov. 13, 2013 and62/053,784 filed on Sep. 22, 2014. The disclosures of the aboveapplications are incorporated herein by reference in their entirety.

FIELD

The present disclosure relates generally to welding apparatuses, andmore particularly to arc welding apparatuses such as Metal Inert Gas(MIG) or Gas Metal Arc Welding (GMAW) welding guns, includingconsumables for generating a welding arc and diffusing a shield gas.

BACKGROUND

The statements in this section merely provide background informationrelated to the present disclosure and may not constitute prior art.

In an arc welding apparatus, such as Metal Inert Gas (MIG) or Gas MetalArc Welding (GMAW) welding gun, a welding wire is fed through thewelding gun to provide a molten metal pool to join metal workpiecestogether. An inert gas is directed through the front (distal) end of thewelding gun to provide a surrounding layer or blanket of shield gas toprotect the molten metal pool from atmospheric contamination. The inertgas is typically a combination of various gases such as argon or helium,among others.

A prior art MIG or GMAW welding gun typically includes a contact tip anda gas diffuser connected to the contact tip. The contact tip has acentral bore to guide the welding wire to the workpieces. The contacttip transfers electrical current to the welding wire. The gas diffuseris typically threaded to the contact tip and defines gas passagewaysthat direct the shield gas into a blanket of shield gas around themolten metal pool. The contact tip and gas diffuser are constantlysubjected to high heat and are susceptible to wear due to hightemperature operation.

SUMMARY

The present disclosure generally provides a contact tip/diffuserconfiguration for an arc welding apparatus, such as an MIG or GMAWwelding gun with an increased consumable life. The various forms of thepresent disclosure provide a simplified structure, more uniform heatdistribution and improved cooling to increase consumable life, amongother benefits.

In one form, a tool repairs an interior surface of a conductor tube foran arc welding apparatus. The tool comprises an elongated body. Theelongated body has a proximal end portion and a distal end portion. Aprofiled end surface extends around the distal end portion of theelongated body. A central protrusion extends distally from the profiledend surface. The profiled end surface of the tool mates within theinterior surface of the conductor tube.

In another form, a tool for repairing an interior surface of a conductortube of an arc welding apparatus. The tool comprises a body with aproximal end portion and a distal end portion. A threaded collar issecured around the proximal end portion of the body. The threaded collaris adapted to engage external threads of the conductor tube. A profiledsurface extends around the distal end portion of the body. A centralprotrusion extends distally from the profiled end surface. The profiledend surface of the tool mates into an interior surface of a distal endportion of the conductor tube.

In yet another form, a method comprises the step for repairing aninterior surface of a conductor tube. The conductor tube defines atapered spherical seat and an internal passageway. The method provides atool having an elongate body with a proximal end portion and a distalend portion. The distal end defines a profiled end surface around thedistal end portion for mating into the tapered spherical seat. A centralprotrusion extends distally from the profiled surface. The methodincludes aligning the central protrusion to extend into the internalpassageway. The tool is positioned with the profiled end surface matingwithin the tapered spherical seat of the conductor tube and the centralprotrusion aligns in the internal passageway. A force is imparted on theproximal end portion of the tool. The force reshapes the taperedspherical seat of the conductor tube to conform around the profiled endsurface to repair the tapered spherical seat.

Further areas of applicability will become apparent from the descriptionprovided herein. It should be understood that the description andspecific examples are intended for purposes of illustration only and arenot intended to limit the scope of the present disclosure.

DRAWINGS

The drawings described herein are for illustration purposes only and arenot intended to limit the scope of the present disclosure in any way.

FIG. 1 is a side view of a prior art arc welding apparatus;

FIG. 2 is a cross-sectional view of a consumable assembly and aconductor tube assembly constructed in accordance with the teachings ofthe present disclosure;

FIG. 3A is a side view of a conductor tube with a conduit liner and anozzle assembly constructed in accordance with the teachings of thepresent disclosure;

FIG. 3B is a side view of a conductor tube with a conduit liner andanother form of a nozzle assembly constructed in accordance with theteachings of the present disclosure;

FIG. 3C is a side view of a conductor tube illustrating the alignmentand a trim distance with an index marking in accordance with theteachings of the present disclosure;

FIG. 4 is a side view of the conductor tube constructed in accordancewith the teachings of the present disclosure;

FIG. 5 is partial side view of a conductor tube assembly constructed inaccordance with the teachings of the present disclosure;

FIG. 6 is a perspective view of one form of a tool constructed inaccordance with the teachings of the present disclosure;

FIG. 7 is a partial side cross-sectional exploded view of the tool ofFIG. 6 aligning with a conductor tube assembly constructed in accordancewith the teachings of the present disclosure;

FIG. 8 is a partial side cross-sectional exploded view of another formof a tool aligning with a conductor tube assembly constructed inaccordance with the teachings of the present disclosure; and

FIG. 9 is a block diagram illustrating a method of using the tool inaccordance with the teachings of the present disclosure.

DETAILED DESCRIPTION

The following description is merely exemplary in nature and is in no wayintended to limit the present disclosure or its application or uses. Itshould be understood that throughout the description and drawings,corresponding reference numerals indicate like or corresponding partsand features. And although the term “MIG” or “GMAW” is used throughoutthe specification, it should be understood that the teachings of thepresent disclosure apply to any type of welding or cutting apparatus.

Referring to FIG. 1, an arc welding apparatus, such as a MIG or GMAWwelding gun, is illustrated and generally indicated by reference numeral10. The MIG welding gun 10 includes a handle 12, a conductor tube 14attached to the handle 12, and a consumable assembly 16 attached to theconductor tube 14. The handle 12 is connected to a welding cable 18 thatcarries welding current, shielding gas, and a welding wire 20 from apower source (not shown), a gas source (not shown), and a wire feeder(not shown) to the welding gun 10.

The consumable assembly 16 includes a plurality of consumable componentsincluding a nozzle assembly 22 and a contact tip 24 that fits inside thenozzle assembly 22. The structure and operation of an exemplary arcwelding apparatus has been disclosed in U.S. Pat. Nos. 5,491,321 and5,338,917, which are commonly owned by the assignee of the presentapplication, and the contents of which are incorporated herein byreference in their entirety. In addition, the structure and operation ofthe arc welding apparatus 10 incorporating a contact tip that providesfor the function as a contact tip and a diffuser has been disclosed inrelated U.S. Published Application No. 2013/0126506, titled “GasDiffuser for GMAW Manual/Robotic Arc Welding MIG Guns,” which iscommonly owned by the assignee of the present application, and thecontents of which are incorporated herein by reference in theirentirety.

Referring to FIG. 2, the consumable assembly 16 includes a contact tip24 and the nozzle assembly 22. The nozzle assembly 22 is secured to theconductor assembly 40. As shown, the nozzle assembly 22 is secured to adistal end portion 26 of the conductor tube 14. The nozzle assembly 22is substantially cylindrical in one form and receives the distal endportion 26 of the conductor tube 14 therein. In one form, a contact tip24 is coaxially disposed inside the nozzle assembly 22. The nozzleassembly 22 further includes a seating surface 28 that is configured tomate with an end portion 30 of the contact tip 24 (which in one form isspherical as shown, but could be any shape including a linear orpolynomial taper) into the distal end portion 26 of the conductor tube14.

In one form the nozzle assembly 22 is secured onto the distal end 26 ofthe conductor tube assembly 40, and the contact tip 24 engages andpresses against the seating surface 28 of a nozzle insert 44. As thenozzle assembly 22 is tightened onto the conductor tube assembly 40, theseating surface 28 engages against the shoulder 46 of the contact tip24, thereby urging the spherical tapered end 48 of the contact tip 24into the spherical tapered seat 50 of the conductor tube 14. The nozzleinsert 44 tightens onto the conductor tube assembly 40 and the sphericaltapered end 48 of the contact tip 24 is secured into engagement with thetapered seat 50.

Also seen in FIG. 2, the conductor tube 14 defines an internalpassageway 52, and a conduit liner 54 is disposed within the internalpassageway 52 as shown. The conduit liner 54 has a guiding channel 56for guiding the welding wire 20 (not shown) to the contact tip 24. Theconduit liner 54 preferably extends into an internal cavity 58 of thecontact tip 24. The positioning of the conduit liner 54 within theinternal cavity 58 provides a continuous guiding channel 56 for directlyfeeding the welding wire into the contact tip 24. Proper positioning ofthe conduit liner 54 within the contact tip 24, or “stick-out” relativeto the distal end portion 26 of the conductor tube 14, is a factor forthe correct operation of the welding torch 10. The conduit liner 54directs the welding wire 20 through the welding cable 18, torch 10,conductor tube 14, and into the contact tip 24.

Additional aspects of the location and features of the conduit liner 54within the internal cavity 58 of the contact tip 24 has been disclosedin U.S. Published Application No. 2013/0126504 A1, which is commonlyowned by the assignee of the present application, and the contents ofwhich are incorporated herein by reference in their entirety.

Referring to FIGS. 3A-3C, the conductor tube 14 can define a variety ofgeometries, and a curved geometry bending of various degrees is useddepending on the application requirements. The conductor tube 14alternatively could be straight or flexible and configurable as has beendisclosed in U.S. Published Application No. 2007/0284354, which iscommonly owned by the assignee of the present application, and thecontents of which are incorporated herein by reference in theirentirety. The conductor tube assembly 40 extends a length between itsdistal end 41 and its proximal end 51. The proximal end 51 is adapted tobe secured to the handle 12 of the welding gun 10, and the distal end 41of the conductor tube 14 is adapted to receive the consumable assembly16 (as shown in FIG. 1).

The distal end 41 of the conductor tube 14 provides unique features toallow for an efficient and robust connection with the consumableassembly 16, the nozzle assembly 22, and the contact tip 24. Forexample, and is best seen in FIG. 3, in one form the distal end 41 hasan outer surface 49 that includes two opposing flat faces 59, thatallows for an anti-rotational engagement with a sleeve (not shown), theflat faces segment the otherwise curved outer surface 22. Additionally,in another form, the distal end 41 has a threaded opening 62 through atleast one of the flat faces 59 for securing the sleeve.

As shown in FIG. 3B, the conductor tube 14 is typically made from acopper alloy or other metal that has conductive properties and then iscoated with an insulation material 64, which in one form may besilicone, and finally covered with a tube jacket 66 to providedurability and additional insulation from the electric current, whichflows through the conductor tube 14 during operation of the welding gun10. The tube jacket 66 by way of example may be made from a brass orstainless steel metal or alloy in one form of the present disclosure.

As shown in FIGS. 4 and 5, the conductor tube assembly 40 includes thesleeve 60 that slides over the profile of the outer surface 49 of theconductor tube 14, as previously set forth. The sleeve 60 is secured tothe conductor tube 14 in one form by the set screw 64 that is engagedthrough a threaded aperture 61 of the sleeve 60. The threaded aperture61 is aligned with the threaded opening 62 of the conductor tube 14, andthe set screw 64 removably secures the sleeve 60 in position over thedistal end 48 of the conductor tube 42. The sleeve defines an exteriorthreads 65 for securing the consumable assembly 16.

Referring to FIGS. 6 and 7, an additional aspect of the presentdisclosure includes an indent tool 70 that can be used to repairdeformation and wear damage to the spherical tapered seat 50 within theconductor tube 14. The indent tool 70, in one form, comprises anelongated body 72 having a proximal end portion 74 and a distal endportion 76. The distal end portion defines an external surface. Theexternal surface of the indent tool 70 defines a profiled end surface78. The profiled end surface 78 matches against an interior surface 80of the distal end portion 26 of the conductor tube 14, which in one formis spherical. The indent tool 70 comprises a central protrusion 82 thatextends distally from the profiled end surface 78. The centralprotrusion 82 has a smaller diameter than the profiled end surface. Thecentral protrusion extends into the internal passageway 52 of theconductor tube 14 to assist a user in positioning the indent tool 70 inproper alignment with the spherical tapered seat 50 of the conductortube 14. The central protrusion 82 may also utilize the channel guide 56to assist with aligning the tool 70 within the spherical tapered seat50. Once the indent tool 70 is in place and properly aligned within theconductor tube 40, a user imparts a force or strike to the proximal endportion 74 with a hammer or other tool (not shown). Since the conductortube 14 is typically made from a rather malleable metal, such as acopper alloy, the user is able to repair minor wear and tear deformitiesin the distal end and the spherical tapered seat 66 by applying animpact force to the proximal end portion 188 of the indent tool 184.

In addition, the distal end portion 76 may further define additionalfeatures that may allow for aligning and controlling the depth of thetool into the spherical tapered seat. For example, the indent tool canfurther include a shoulder 84 that defines a flange 86. The flange mayprovide a stop surface against a distal end face 88 of the conductortube 14. As best seen in FIG. 6, the distal end portion 76 furtherdefines a spaced distance 87 between the profiled end surface 78 and theflange 86. Therefore, the profiled end surface in an unrepairconfiguration is in contact with the interior surface 80 and the flange86 is the spaced distance 87 from the distal end face 88 of theconductor tube 14. After the imparted force the indent tool 70 is drivenproximally into the interior surface 80 reshaping the spherical taperedseat 50 by the profiled end surface 78. The distance between the flange86 and the distal end face 88 decreases to define a repairedconfiguration. The flange 86 of the tool 70 therefore defines a maximumstrike distance the tool 70 can be driven into the interior surface 80of the conductor tube 14 when the flange 86 abuts the distal end face88. It is appreciated that the tool may incorporate numerous features toassist the user with maintaining the alignment to reshape the sphericaltapered seat 50.

Referring to FIG. 8, in another form, an indent tool 170 comprises abody 172 having a proximal end portion 174 and a distal end portion 176.In this form, the indent tool 170 includes a threaded collar 190 that issecured around the proximal end portion 174 of the body 172. Thethreaded collar 190 is adapted to engage with the external threads 204of the sleeve 60 on the conductor tube assembly 14. As discussed in theform above, the indent tool 170 includes a profiled end surface 178extending around the distal end portion 176 of the body 196. Theprofiled end surface 178 matches the interior surface 80 of the distalend portion 26 of the conductor tube 14. The indent tool 170 alsoincludes a central protrusion 182 that extends distally from theprofiled end surface 178. In operation, the central protrusion 182extends into the internal passageway 52 as already discussed above. Theuser tightens the threaded collar 190 onto the external threads 204 ofthe sleeve 60, and the tightening force imparts a force that can reshapeand repair the spherical tapered seat 50 in the malleable metal of theconductor tube 42. The threaded collar 190 may be of various shapesincluding hexagonal to allow for user to torque with a wrench or othertorque or driving tool. It is appreciated that various outside shapesand textures to the thread collar may be used to provide the needed gripor to further allow for the intent tool to be engaged with a wretch toincrease the force.

Referring to FIG. 9 the steps of a method 300 for repairing an interiorsurface 80 and the spherical tapered seat 50 of a conductor tube 14. Afirst step 302 is providing a tool 70 with a body 72 that defines aproximal end portion 76 and a distal end portion having a profiled endsurface. A second step 304, the user aligns the central protrusion toextent into the internal passageway. Optionally, the central protrusionmay engage with the channel guide 56 to assist a user in maintainingproper alignment between the tool and the conductor tube. A third step306, the users positions the profiled end surface within the taperedspherical seat 50. A fourth step 308, the method imparts a force on theproximal end portion of the tool. The imparted force drives the toolinto the spherical tapered seat. The fifth step 310, the tool reshapesthe tapered spherical seat 50 of the conductor tube 14 to conform aroundthe profiled end surface 78. The impact and reshaping allows forrepairing minor damage to the malleable material of the conductor tube14. The imparted load may be in the form of an impact on the proximalend portion 74 or in another form the imparted force may be from atorque as the threaded collar 202 is turned into engagement with thethreads 204 of the sleeve 60.

The present disclosure is merely exemplary in nature and, thus,variations that do not depart from the spirit of the disclosure areintended to be within the scope of the present disclosure. Suchvariations are not to be regarded as a departure from the scopecontemplated in the present disclosure.

1. A method for repairing an interior surface of a conductor tube, theconductor tube includes a tapered spherical seat and an internalpassageway, the steps of the method comprising: providing a tool havingan elongate body having a proximal end portion and a distal end portiondefining a profiled end surface around the distal end portion for matinginto the tapered spherical seat and a central protrusion extendingdistally from the profiled surface; aligning the central protrusion toextend into the internal passageway; mating the profiled end surfacewith the tapered spherical seat of the conductor tube and the centralprotrusion in the internal passageway; imparting an force on theproximal end portion of the tool; and reshaping the tapered sphericalseat of the conductor tube to conform around the profiled end surfacefrom the force causing the interior surface of the conductor tube torepair the tapered spherical seat.
 2. (canceled)
 3. The method accordingto claim 1, wherein the step of imparting a force is further defined asstriking the proximal end portion.
 4. The method according to claim 1,wherein the distal end portion of the tool further defines a shoulderand a flange, and wherein the profiled end surface extends distally fromthe flange.
 5. The method according to claim 4, wherein the flange abutsa distal end face of the conductor tube after imparting the force ontothe proximal end of the tool and defines a maximum distance the tool canbe driven into the interior surface of the conductor tube.
 6. The methodaccording to claim 4, wherein the distal end portion further defines aspaced distance between the profiled end surface and the flange.
 7. Themethod according to claim 6, wherein an unrepaired configuration of theconductor tube is defined as when the profiled end surface is in contactwith the interior surface of the conductor tube and the flange is atleast the spaced distance from a distal end face of the conductor tube.8. The method according to claim 7, wherein a repaired configuration ofthe conductor tube is defined as when the profiled end surface is incontact with the interior surface of the conductor tube and the flangeis less than the spaced distance from the distal end face of theconductor tube.
 9. A method for repairing an interior surface of aconductor tube, the conductor tube includes a tapered spherical seat andexternal threads, the steps of the method comprising: providing a toolhaving a body with a proximal end portion and a distal end portion, theproximal end portion defining a threaded collar disposed around theproximal end portion and configured to engage the external threads ofthe conductor tube, and the distal end portion defining a profiled endsurface around the distal end portion for mating into the taperedspherical seat and a central protrusion extending distally from theprofiled surface; threading the threaded collar of the tool onto theexternal threads of the conductor tube to impart an force onto thetapered spherical seat of the conductor tube with the profiled endsurface of the distal end portion of the tool; and reshaping the taperedspherical seat of the conductor tube to conform around the profiled endsurface from the force causing the interior surface of the conductortube to repair the tapered spherical seat.
 10. The method of claim 9,wherein an outer surface of the threaded collar is hexagonal.
 11. Themethod of claim 9, wherein the distal end portion of the tool furtherdefines a shoulder and a flange, and wherein the profiled end surfaceextends distally from the flange.
 12. The method according to claim 11,wherein the flange abuts a distal end face of the conductor tube afterthreading the threaded collar onto the external threads of the conductortube and defining a maximum distance the profiled end surface of thetool can be tightened into the interior surface of the conductor tube.13. The method according to claim 11, wherein the distal end portionfurther defines a spaced distance between the profiled end surface andthe flange.
 14. The method according to claim 13, wherein an unrepairedconfiguration of the conductor tube is defined as when the profiled endsurface is in contact with the interior surface of the conductor tubeand the flange is at least the spaced distance from a distal end face ofthe conductor tube.
 15. The method according to claim 13, wherein arepaired configuration of the conductor tube is defined as when theprofiled end surface is in contact with the interior surface of theconductor tube and the flange is less than the spaced distance from thedistal end face of the conductor tube.
 16. A method for repairing aninterior surface of a conductor tube, the conductor tube includes atapered spherical seat, the steps of the method comprising: aligning aprofiled end surface of a distal end portion of a tool with the taperedspherical seat of the conductor tube; imparting a force onto the tool todrive the profiled end surface into the tapered spherical seat of theconductor tube; and reshaping the tapered spherical seat of theconductor tube to conform around the profiled end surface from the forcecausing the interior surface of the conductor tube to repair the taperedspherical seat.
 17. The method according to claim 16, wherein impartinga force is further defined as tightening a threaded collar over athreaded portion of the conductor tube.
 18. The method according toclaim 17, wherein the threaded collar is hexagonal and disposed around aproximal end of the tool.
 19. The method according to claim 16, whereinimparting a force is further defined as striking a proximal end portionof the tool.
 20. The method according to claim 16, wherein the distalend portion of the tool further defines a shoulder and a flange, andwherein the profiled end surface extends distally from the flange. 21.The method according to claim 20, wherein the flange abuts a distal endface of the conductor tube after imparting the force onto the tool anddefining a maximum distance the profiled end surface of the tool can bedriven into the interior surface of the conductor tube.